PRODUCT SUPPORT PROGRAM FOR REWORKING THE 200-1058 FORE BOOM EARS ON CERTAIN HYDRAULIC EXCAVATORS EQUIPPED WITH HYDRAULIC ADJUSTABLE BOOMS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE 200-1058 FORE BOOM EARS ON CERTAIN HYDRAULIC EXCAVATORS EQUIPPED WITH HYDRAULIC ADJUSTABLE BOOMS [REBE4294]

IMPLEMENTS

BOOM GP

PRODUCT SUPPORT PROGRAM FOR REWORKING THE 200-1058 FORE BOOM EARS ON CERTAIN HYDRAULIC EXCAVATORS EQUIPPED WITH HYDRAULIC ADJUSTABLE BOOMS

REBE4294-00

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26Aug2008

U-443

O-403

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE 200-1058 FORE BOOM EARS ON CERTAIN HYDRAULIC EXCAVATORS EQUIPPED WITH HYDRAULIC ADJUSTABLE BOOMS
6516 6501		PS51542

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS51542" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

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NOTE:

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your AVSpare product analyst.

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TERMINATION DATE

31Aug2012

PROBLEM

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The existing 200-1058 Fore Boom can crack around the fore boom cylinder ears on certain 312C Hydraulic Excavators. If the existing fore boom is not repaired in a timely manner, the cracks may propagate and cause further damage to the fore boom.

AFFECTED PRODUCT

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Model	Identification Number
312C	BNN00469 CBT00330, 334, 363, 367, 371, 373-375, 392-393, 409, 411, 413, 420-421, 426, 431, 433, 440, 442, 452, 454, 467, 471, 481-483, 487, 490, 492, 495, 498, 507, 509, 512, 521, 530, 533, 538, 546, 564, 569, 573, 580, 587, 592-593, 596, 624, 634, 656-657, 662, 664-665, 678, 694, 699-700, 715, 721, 739, 759, 763, 770, 776, 788, 794, 826, 834, 836, 841, 843, 848, 852, 854, 868, 871, 890, 903, 909 DBN00212, 414-417, 1178
312C L	BWH00240, 268-269, 271, 298-299, 309, 311, 325, 327-329, 338, 354, 358, 362, 365, 370, 372, 374, 387, 391, 393, 408, 411, 417, 428-429, 436, 440-441, 462, 471, 479, 484, 486-488, 500, 525-526, 532, 534-535, 539-540, 542, 547-549, 556, 567, 570, 583, 598, 603-606, 614, 641-642, 646, 681, 685, 708, 710, 731, 791, 799, 801, 806, 808, 833, 846, 848, 857, 859, 867, 878-879, 882, 886, 888, 890, 895, 1050-1051, 1074, 1095, 1100, 1127, 1152, 1166, 1189, 1191, 1193, 1195, 1201, 1205, 1209, 1226, 1244, 1257, 1262, 1266, 1270, 1280, 1290, 1293, 1296-1297, 1304, 1310, 1317, 1320, 1340, 1343, 1354, 1365-1366, 1371, 1399, 1404, 1442, 1454, 1456, 1466, 1468, 1470, 1489, 1509, 1514, 1517, 1546, 1561, 1617, 1661, 1681, 1734, 1762-1763, 1777, 1781, 1811

PARTS NEEDED

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Qty	Part Number	Description
2	PLATE	Dealer Fabricated

ACTION REQUIRED

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If the crack is not propagating out of the welds as shown in the below picture, apply the attached rework procedure.
If the crack is propagating out of the weld into the plate, please take pictures. Submit this information to the Dealer Solution Network (DSN) through your Technical Communicator in order to obtain the information that is necessary to complete any repairs, making sure to reference this service letter program number in the Service Request.

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Image1

SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-3000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
3001-5000 hrs, 25-48 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

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NOTE: This is a 6.0-hour job
A maximum of $300.00 U.S. will be allowed for materials and labor to fabricate the plates listed in the parts needed section.

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PARTS DISPOSITION

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Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

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1. Place the machine on flat, level ground.
2. Activate the implements to position the fore boom to ensure that the reworked area in on a horizontal plan - See Image 1.1.1.

Image1.1.1

3. Release the hydraulic circuit pressure from the hydraulic circuit. Refer to Testing and Adjusting Manual, RENR5509, "Hydraulic System Pressure - Release".
4. Remove the key which starts the machine, secure the cab, and disconnect all power and ground leads from the batteries in order to avoid possible damage to the electronic components.
5. Remove the fore boom cylinder.
6. Protect finish bores and surfaces from spatter when welding.
7. Remove the cracked area by arc air method or grinding (grind the gouged area if arc air method is used to remove slag or carbon pickup).
8. Use dye penetrant to make sure that the crack is completely removed, or the repair could fail.
9. Reweld the gouged/ground area.
10. Manufacture 2 reinforcement plates according to Image 1.2.1.

Image1.2.1

11. Hold the first reinforcement plate and tack weld on the end of the plate (location 1). Check the alignment with the existing plate using a level.
Make the second tack weld on the other end of the plate (location 2). Recheck the alignment.
Make additional tack welds to hold the reinforcement plate in position before the final welds are made (locations 3,4,5,6).

Image1.3.1

12. Weld from point A to point B on both sides (10 mm bevel joint - see Image 1.4.1). Build the deposit up equally on each side of the joint to allow contractive forces to balance each other and prevent distorsion. Grind this weld so that the surface is flush with the ear.
13. Weld from point B to point C on both sides (8 mm fillet weld) - See Image 1.4.1.
14. Weld on point A - See detail A of Image 1.4.1.
15. Weld on point C - See detail B of Image 1.4.1.
16. Grind toes of the welds on point A and point C to get a smooth transition profile.
17. Repeat steps 6 to 13 for the second reinforcement plate.
18. Paint the repaired area.
19. Reassemble the fore boom cylinder.
20. Reconnect the power and ground leads from the batteries.